Repair Procedures

Removal

Parking Brake Lever

NOTE:
The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure.

1. Remove the floor console.

2. Loosen the adjusting nut (A) and the parking brake cables.

3. Disconnect the connector (A) of parking brake switch.

4. Remove the parking brake lever assembly (A) with loosening the bolts.

Parking Brake Shoe
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the rear tire and wheel.
3. Remove the brake caliper and Rear disc brake.

4. Remove the parking brake cable (B), after removing the bolt (A).

Tightening torque :
53.9 - 63.7 N.m (5.5 - 6.5 kgf.m, 39.8 - 47.0 lb-ft)

5. Remove the shoe hold down pin (A) and the spring (B) by pushing the retainer spring and turning the pin.

6. Remove the adjuster assembly (B) and the lower return spring (A).

7. Remove the upper return spring (C) and the brake shoes (D).

8. Remove the operating lever assembly (E).

Installation

Parking Brake Shoe
1. Install the operating lever assembly (E).

2. Install the upper return spring (C) and the brake shoes (D).
3. Install the adjuster assembly (B) and the lower return spring (A).

4. While pressing the spring, install the brake shoe hold down pin (A) and spring (B).

5. Install the parking brake cable (B), then install the bolt (A).

NOTE:
How to install the DIH cable (Quick Fit type)
1. Put the inner cable into the knuckle hole in DIH lever operating direction when installing the cable (B).
2. Confirm by pulling the cable that cable is fixed certainly before installing the bolt (A).

6. Install the rear brake disc, then adjust the rear brake shoe clearance.
(1) Remove the plug from the disc.

(2) Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 5 notches in the opposite direction.
(3) Install the plug.
7. Install the brake caliper assembly.
8. Install the tire and wheel.
9. If the parking brake shoe or the brake disc are replaced a newly one, perform the brake shoe bed-in procedure.
(1) While operating the parking brake pedal for 69N (7kgf, 15lbf) effort, drive the vehicle 500 meters (0.31 miles) at the speed of 60kph (37.3 mph).
(2) Repeat the above procedure more than two times.
(3) Must be held on at 30% uphill.

CAUTION:
After adjusting parking brake, notice following matter;
1. Must be free from troubles when the parking pedal is operated at 686 N (70 kgf, 154 lb).
2. Check that all parts move smoothly.
3. The parking brake indicator lamp must be on after the parking pedal is worked and must be off after the pedal is released.

Parking Brake Lever
1. Install the parking brake lever assembly, then tighten the mounting bolts in alphabetic order.

Tightening torque :
8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb-ft)

2. Apply a coating of the specified grease to each sliding parts (A) of the ratchet plate or the ratchet pawl.

Specified grease :
Multi purpose grease RheoGel 429 (MS511-54, LT2)

3. Install the parking brake cable adjuster, then adjust the parking brake lever stroke by turning adjusting nut (A).

Parking brake lever stroke :
5 clicks (Pull the lever with 20kg)

NOTE:
After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake lever stroke.

4. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are turned. Readjust if necessary.
5. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
6. Reconnect the connector (A) of parking brake switch.

NOTE:
Inspect the continuity of parking brake switch.

When the brake lever is pulled : continuity
When the brake lever is released : no continuity

7. Install the floor console.

Adjustment

Parking Brake Shoe Clearance Adjustment
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the rear tire and wheel.
3. Remove the plug from the disc.

4. Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 5 notches in the opposite direction.
5. Install the plug on disc and then rear wheel & tire.

Parking Brake Lever Stroke Adjustment
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the floor console.

3. Adjust the parking brake lever stroke by turning adjusting nut (A).

Parking brake lever stroke :
5 clicks (Pull the lever with 20kg)

NOTE:
After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake lever stroke.